Effects of Minimum Quantity Lubrication (MQL) on cutting temperature, tool wear and surface roughness in turning AISI-1045 material

Abstract

The effects of cutting fluids to health, environment, productivity and quality in machining operations have been discussed. MQL is green technology which is gradually applied in mechanical processing. The article has introduced about MQL cooling lubrication method in mechanical processing. Some previous research result have been made to clarify the meaning of this method. In addition, the comparison of the outputs of MQL, dry and wet methods has also been shown to show the effectiveness of the MQL method. Then, based on the MQL equipment being used at Tran Dai Nghia University, the authors designed the experiment to evaluate the impact of MQL parameters on the process outputs. Machining and optimization of that parameter. This paper presents of the MQL parameters optimization approach in which the multi-response outputs based on Taguchi's L9 orthogonal array method is used. During the turning AISI-1045 steel, the cutting temperature, the maximum of tool wear, and the surface roughness were measured. The MQL parameters which are ratio of soluble lubricant and water, pressure of spray head, flow volume of emulsion was simultaneously optimized by taking the multi-response outputs using Taguchi based grey relational analysis (GRA) into consideration. In turning experiments, three different flow volume of emulsion Q (40, 60, 80 ml/h), three different levels pressure of spray head P (3, 5, 7 bar) and three different levels ratio of soluble lubricant and water R (4, 6, 8%) were used. Here, three mathematical models were created using response surface regression methodology. The experiments had been done to investigate the effect of the MQL parameters to the turning process. As the results, the set of optimal MQL parameters had been pointed out to simultaneously minimize the cutting temperature, the tool wear and surface roughness. The Flow volume of emulsion 80 ml/h, Pressure of spray head 7 bar, Ratio of soluble lubricant and water 6% was observed to be the most effective. Lubrication (MQL) on cutting temperature, tool wear and surface roughness in turning AISI-1045 material. Sci. Tech. Dev. J. -Engineering and Technology; 2(SI):xxx-xxx. 1 U n c o r r e c t i o n P r o o f Science & Technology Development Journal -Engineering and Technology, 2(SI):xxx-xxx tionally, the machining of parts uses flood cooling in 36 which the jet of coolant is directed toward the cutting 37zone. Here, the coolant is deployed in large quantities. 38There are several disadvantages to using this method. 39The first one has to do with the cost of machining 40 and its disposal. Approximately fifteen percent of to-41 tal cost in machining is incurred by the coolant and 42 its disposal. The second one deals with a safety issue 43 for the operators. One problem that exists for opera-44 tors is that when they stay in contact with the coolant 45 for a long time, it may cause skin problems. The third 46 one is the effect on the environment. After machin-47

Effect of R410a coolant on tool wear, dimensional deviation and surface roughness in turning of AISI 1045 steel

“…Aleksandrovich et al [42] examined the effect of tool construction and cutting parameters on surface roughness and vibration in turning AISI 1045 steel using the Taguchi method. Modeling and optimization techniques such as ANOVA and RSM have been utilized to optimize machining conditions for AISI 1045 steel [43][44][45]. Hernández González et al [26,27] applied response surface methodology (RSM) to identify the best cutting conditions for minimizing flank wear in highspeed dry turning of AISI 1045 steel.…”